Flapper valve tool

ABSTRACT

The present invention is related to a downhole tool having a flapper valve assembly for controlling the backflow of fluid into a tubing string. The downhole tool includes a first sleeve slidably disposable within at least a portion of the flapper valve assembly and the downhole tool. The downhole tool can also include a second sleeve slidably disposed within the downhole tool. The present invention is also related to a method of using the downhole tool. The method includes the step of positioning the downhole tool in a wellbore. Once the downhole tool is positioned in the wellbore, the first sleeve is shifted to interact with the flapper valve assembly.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a conversion of U.S. Provisional Applicationhaving U.S. Ser. No. 62/038,049, filed Aug. 15, 2014, which claims thebenefit under 35 U.S.C. 119(e), the disclosure of which is herebyexpressly incorporated herein by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND OF THE DISCLOSURE

1. Field of the Invention

The present disclosure relates to a downhole tool used to control and/orprevent pressurized wellbore fluids from traveling up through theworkstring tubing.

2. Description of the Related Art

Traditionally, flapper valves have been used to prevent pressurizedwellbore fluids from entering a workstring from the bottom up. Typicalflapper valves can wear out after a period of use.

Accordingly, there is a need for a way to be able to reliably maintain aflapper valve in an open position.

SUMMARY OF THE DISCLOSURE

The disclosure is related to a downhole tool having a flapper valveassembly for controlling the backflow of fluid into a tubing string. Thedownhole tool also includes a first sleeve slidably disposable within atleast a portion of the flapper valve assembly and the downhole tool. Thedownhole tool can also include a second sleeve slidably disposed withinthe downhole tool.

The disclosure is also related to a method of using the downhole tool.The method includes the step of positioning the downhole tool in awellbore. Once the downhole tool is positioned in the wellbore, thefirst sleeve is shifted to interact with the flapper valve assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1C are cross-sectional views of one embodiment of a downholetool constructed in accordance with the present invention.

FIGS. 2A-2C are cross-sectional views of another embodiment of thedownhole tool constructed in accordance with the present invention.

FIG. 3 is a cross-sectional view of yet another embodiment of thedownhole tool constructed in accordance with the present disclosure.

FIGS. 4A and 4B are cross-sectional views of the embodiment of thedownhole tool shown in FIG. 3 in a second position and constructed inaccordance with the present disclosure.

FIGS. 5A and 5B are cross-sectional views of the embodiment of thedownhole tool shown in FIG. 3 in a third position and constructed inaccordance with the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure relates to a flapper valve tool 10 that can bedesigned and implemented into a bottom hole assembly (BHA) that has atleast one sleeve disposed therein to either open a flapper 14 or permitthe flapper 14 to close.

In one embodiment of the present disclosure shown in FIGS. 1A-1C, theflapper valve tool 10 includes a top sub 16 for connecting to othertools disposed above the flapper valve tool 10 in the BHA, a bottom sub18 for connecting the flapper valve tool 10 to other tools disposedbelow the flapper valve tool 10 in the BHA and a housing 20 (or body)connecting the top sub 16 to the bottom sub 18. In this embodiment, theflapper valve tool 10 includes a closing sleeve 12 slidably disposed inthe housing 20 and a flapper assembly 22 disposed in the housing 20.

The flapper assembly 22 includes a flapper 14 for selectively blockingthe backflow of fluid through the flapper valve tool 10 and a flapperseat 24 disposed in the housing 20 such that the closing sleeve 12 canslide through the flapper seat 24. The flapper 14 sits against theflapper seat 24 when the flapper 14 is in the closed position andprevents pressurized fluid from flowing in the uphole direction throughthe flapper valve tool 10. The flapper 14 can be hingedly connected tothe flapper seat 24 or to the inside of the housing 20.

The closing sleeve 12 shown in FIGS. 1A-1C includes a collar 26 disposedaround an outside portion of the closing sleeve 12 and the flapper valvetool 10 includes a shoulder 28 disposed therein to engage the collar 26and prevent further sliding movement of the closing sleeve 12 when theclosing sleeve 12 is shifted from a first position in the flapper valvetool 10 to a second position in the flapper valve tool 10. The shoulder28 can be disposed on the inside of the bottom sub 18 or the housing 20of the flapper valve tool 10. The closing sleeve 12 can be held in thefirst position in the flapper valve tool 10 via any means known in theart, such as shear pins 30. The closing sleeve 12 can also include a lip32 disposed around a portion of the inside of the closing sleeve 12 tocreate a seat for a fluid blocking member 34 to engage and not be ableto pass completely through the closing sleeve 12.

FIG. 1A shows the closing sleeve 12 in its first position and holdingthe flapper 14 in an open position. FIG. 1B shows the fluid blockingmember 34 engaged with the lip 32 of the closing sleeve 12 and theclosing sleeve 12 in its second position in the flapper valve tool 10.When enough pressure is put behind the fluid blocking member 34, theshear pins 30 fail and permit the closing sleeve 12 to move from itsfirst position to its second position in the flapper valve tool 10. Theclosing sleeve 12 will travel a predetermine distance before the collar26 of the closing sleeve 12 impacts the shoulder 28 disposed on theinside of the flapper valve tool 10, which prevents further movement ofthe closing sleeve 12 in the flapper valve tool 10. After the closingsleeve 12 travels a specific amount, the flapper 14 is no longerprevented from closing and the flapper 14 closes against the flapperseat 24 to prevent fluid from flowing in the uphole direction throughthe flapper valve tool 10. If desired, high pressure fluid can be pumpeddown to force the fluid blocking member 34 past the lip 32 in theclosing sleeve 12, as can be seen in FIG. 1C. As the fluid blockingmember 34 is forced past the lip 32, a deformed portion 33 is created inthe closing sleeve 12 due to the force and pressure required to forcethe fluid blocking member 34 past the lip 32 in the closing sleeve 12.The deformed portion 33 of the closing sleeve 12 extends into adepression area 35 disposed on the inner portion of the housing 20 orbottom sub 18 and prevents the closing sleeve 12 from traveling in theuphole direction in the flapper valve tool 10.

In another embodiment of the present disclosure shown in FIGS. 2A-2C,the flapper valve tool 10 includes an opening sleeve 36 (as opposed tothe closing sleeve 12) that has a first position where the flapper 14 isset against the flapper seat 24 (closed). Consequently, the flapper 14is in the open position when the opening sleeve 36 is in its secondposition. The opening sleeve 36 has a lip 38 disposed around an innerportion 40 of the opening sleeve 36 and a collar 42 disposed around anouter portion 44 of the opening sleeve 36. The lip 38 is designed toprovide a seat for engaging with the fluid blocking member 34. Thecollar 42 is designed to engage with a shoulder 46 disposed within theflapper valve tool 10. In one embodiment, the collar 42 is disposed onan uphole end 48 of the opening sleeve 36 to engage the shoulder 46,which can be disposed on an inner portion of the housing 20 or a part ofa flapper body 50 of the flapper assembly 22. Similar to the closingsleeve 12, the opening sleeve 36 can be held in place via shear pins 30.

FIG. 2A shows the opening sleeve 36 in its first position wherein theflapper 14 is in the shut position and set against the flapper seat 24restricting fluid from flowing in the uphole direction through theflapper valve tool 10. FIG. 2B shows the fluid blocking member 34engaged with the lip 38 of the opening sleeve 36 and the opening sleeve36 in its second position in the flapper valve tool 10. When enoughpressure is put behind the fluid blocking member 34, the shear pins 30fail and permit the opening sleeve 36 to move from its first position toits second position in the flapper valve tool 10. The flapper valve tool10 will travel a predetermined distance before the collar 42 of theopening sleeve 36 impacts the shoulder 46 disposed on the inside of theflapper valve tool 10, which prevents further movement of the openingsleeve 36 in the flapper valve tool 10.

After the flapper valve tool 10 travels a specific amount, a downholeend 52 of the opening sleeve 36 contacts the flapper 14 and forces theflapper 14 into the open position as the opening sleeve 36 moves intoits second position. This allows fluid to now flow in the upholedirection through the flapper valve tool 10. If desired, high pressurefluid can be pumped down to force the fluid blocking member 34 past thelip 38 in the opening sleeve 36 as can be seen in FIG. 2C. As the fluidblocking member 34 is forced past the lip 38, a deformed portion 37 iscreated in the opening sleeve 36 due to the force and pressure requiredto force the fluid blocking member 34 past the lip 38 in the openingsleeve 36. The deformed portion 37 of the opening sleeve 36 extends intoa depression area 39 disposed on the inner portion of the housing 20 andadjacent to the flapper seat 24. The deformed portion 37 being widerthan the flapper valve seat 24 prevents the opening sleeve 36 fromtraveling in the uphole direction in the flapper valve tool 10.

The fluid blocking member 34 can be pumped out of the flapper valve tool10 and into some type of collection area so that fluid is permitted toflow in the uphole direction in the flapper valve tool 10. In a furtherembodiment, the downhole end 52 of the opening sleeve 36 can be angledsuch that opening the flapper 14 is significantly easier. The angle inthe downhole end 52 of the opening sleeve 36 is designed such that thelonger portion of the opening sleeve 36 contacts the flapper 14 on theopposite side of the flapper 14 from where the flapper 14 is hinged.

In yet another embodiment of the present disclosure shown in FIGS. 3-5B,the flapper valve tool 10 can be designed such that it has a firstposition where the flapper 14 is in an open position (see FIG. 3), asecond position where the flapper 14 is in a closed position (see FIGS.4A and 4B) and a third position where the flapper 14 is back in the openposition (see FIGS. 5A and 5B). The flapper valve tool 10 includes thetop sub 16, the bottom sub 18 and the housing 20, as previouslydescribed herein. The flapper valve tool 10 also includes the flapperassembly 22, the closing sleeve 12, and the opening sleeve 36, asdescribed herein. The closing sleeve 12 is positioned downhole of theopening sleeve 36 in the flapper valve tool 10. Furthermore, the flapperassembly 22 can include the flapper 14, the flapper seat 24 and theflapper body 50, as previously described herein.

In use, the fluid blocking member 34 is pumped into the flapper valvetool 10 to contact the lip 32 in the closing sleeve 12. Fluid ispressured up behind the fluid blocking member 34 to shear pins 30holding the closing sleeve 12 in the first position, which holds theflapper 14 in the open position. Once the shear pins 30 are sheared, theclosing sleeve 12 is forced in the downhole direction inside the flappervalve tool 10 and into a second position for the closing sleeve 12, asshown in FIGS. 4A and 4B. After the closing sleeve 12 travels apredetermined length inside the flapper valve tool 10, the flapper 14will spring shut against the flapper seat 24. Once the closing sleeve 12is in the second position, fluid in the system can be further pressuredup and the fluid blocking member 34 can be forced past the lip 32disposed in the closing sleeve 12 and out of the flapper valve tool 10.FIG. 4B shows the closing sleeve 12 in the second position after thefluid blocking member 34 is pushed out of the closing sleeve 12 of theflapper valve tool 10 and the opening sleeve 36 in its first position.As disclosed herein in previous embodiments, as the fluid blockingmember 34 is forced past the lip 32, a deformed portion 33 is created inthe closing sleeve 12 due to the force and pressure required to forcethe fluid blocking member 34 past the lip 32 in the closing sleeve 12.The deformed portion 33 of the closing sleeve 12 extends into adepression area 35 disposed on the inner portion of the housing 20 orbottom sub 18 and prevents the closing sleeve 12 from traveling in theuphole direction in the flapper valve tool 10. It should be understoodand appreciated that the fluid blocking member 34 is sized such that itcan pass by the lip 38 in the opening sleeve 36 and then engage the lip32 in the closing sleeve 12.

When it is desirous to have the flapper 14 back in the open position, asecond fluid blocking member 54 can be pumped down into the flappervalve tool 10. The second fluid blocking member 54 is pumped down andcontacts the lip 38 in the opening sleeve 36. The fluid in the flappervalve tool 10 is pressured up and shear pins 30 holding the openingsleeve 36 in the opening sleeve's 36 first position are sheared,allowing the opening sleeve 36 to move in the downhole direction in theflapper valve tool 10. As the opening sleeve 36 moves in the downholedirection, the opening sleeve 36 contacts the flapper 14 and forces itopen. When the opening sleeve 36 reaches its second position in theflapper valve tool 10, the opening sleeve 36 prevents the flapper 14from closing and maintains the flapper 14 in the open position, which isshown in FIG. 5.

Once the opening sleeve 36 is in its second position, fluid in thesystem can be further pressured up and the second fluid blocking member54 can be forced past the lip 38 disposed on the opening sleeve 36 andout of the flapper valve tool 10. FIG. 5B shows the closing sleeve 12 inits second position and the opening sleeve 36 in its second positionafter the second fluid blocking member 54 was pushed out of the flappervalve tool 10. Similar to what was previously described herein for otherembodiments, as the fluid blocking member 54 is forced past the lip 38,a deformed portion 37 is created in the opening sleeve 36 due to theforce and pressure required to force the fluid blocking member 54 pastthe lip 38 in the opening sleeve 36. The deformed portion 37 of theopening sleeve 36 extends into a depression area 39 disposed on theinner portion of the housing 20 and adjacent to the flapper seat 24. Thedeformed portion 37 being wider than the flapper valve seat 24 preventsthe opening sleeve 36 from traveling in the uphole direction in theflapper valve tool 10.

The present disclosure is also directed toward a method of controllingthe flapper valve tool 10 and the backflow of fluid from the BHA intoany tubing or tubing string the BHA is attached to. The method caninclude placing the flapper valve tool 10 into a wellbore, activatingthe closing sleeve 12 or the opening sleeve 36 to close or open theflapper 14, respectively. Activation of the closing sleeve 12 or theopening sleeve 36 can be accomplished by pumping the fluid blockingmembers 34, 54 into the flapper valve tool 10 to engage the lips 32, 38of the sleeves 12, 36.

In another embodiment of the present disclosure, the flapper valve tool10 is placed in the wellbore and the closing sleeve 12 is shifted fromits first position to its second position, which causes the flapper 14to transition from an open position to a closed position. The openingsleeve 36 can then be shifted from its first position to its secondposition, which causes the flapper 14 to transition from the closedposition back to the open position.

From the above description, it is clear that the present disclosure iswell adapted to carry out the objectives and to attain the advantagesmentioned herein as well as those inherent in the disclosure. Whilepresently disclosed embodiments have been described for purposes of thisdisclosure, it will be understood that numerous changes may be madewhich will readily suggest themselves to those skilled in the art andwhich are accomplished within the spirit of the disclosure.

What is claimed is:
 1. A downhole tool, the tool comprising: a flappervalve assembly for controlling the backflow of fluid into a tubingstring; a first sleeve slidably disposable within at least a portion ofthe flapper valve assembly and the downhole tool, the first sleeveslidable from a first position to a second position; a second sleeveslidably disposable within at least a portion of the flapper assemblyand the downhole tool, the second sleeve disposed uphole of the firstsleeve in the downhole tool, the second sleeve slidable from a firstposition to a second position; and a deformable portion incorporatedinto the first sleeve that is yieldably deformed to maintain the firstsleeve in substantially the second position.
 2. The tool of claim 1wherein the flapper valve assembly comprises a flapper seat and aflapper that can close against the flapper seat and prevent fluid frompassing in the uphole direction through the downhole tool.
 3. The toolof claim 2 wherein the first sleeve is positioned within the downholetool such that the flapper is in an open position when the first sleeveis in a first position.
 4. The tool of claim 3 wherein the flapper is ina closed position when the first sleeve is in its second position in thedownhole tool.
 5. The tool of claim 4 wherein the first sleeve has aseat disposed therein to engage with a fluid blocking member to shiftthe first sleeve from its first position to its second position.
 6. Thetool of claim 2 wherein the first sleeve is positioned within thedownhole tool such that the flapper is in a closed position when thefirst sleeve is in a first position.
 7. The tool of claim 6 wherein theflapper is in an open position when the first sleeve is in its secondposition in the downhole tool.
 8. The tool of claim 7 wherein the firstsleeve has a seat disposed therein to engage with a fluid blockingmember to shift the first sleeve from its first position to its secondposition.
 9. The tool of claim 1 wherein the flapper valve assemblycomprises a flapper seat and a flapper that can close against theflapper seat and prevent fluid from passing in the uphole directionthrough the downhole tool.
 10. The tool of claim 9 wherein the flapperis in an open position when the first sleeve and the second sleeve arein their respective first positions.
 11. The tool of claim 10 whereinthe flapper is in a closed position when the first sleeve is in itssecond position and the second sleeve is in its first position.
 12. Thetool of claim 11 wherein the flapper is in an open position when thefirst sleeve is in its second position and the second sleeve is in itssecond position.
 13. The tool of claim 12 wherein the first sleeve has aseat disposed therein to engage with a fluid blocking member to shiftthe first sleeve from its first position to its second position and thesecond sleeve has a seat disposed therein to engage with a second fluidblocking member to shift the second sleeve from its first position toits second position.
 14. The tool of claim 1 wherein the second sleevehas an angled end on a downhole end of the second sleeve.
 15. The toolof claim 1 further comprising a second deformable portion that isdeformed to maintain the second sleeve in the second position.
 16. Thetool of claim 15 wherein the second deformable portion is a lip disposedin the second sleeve and once the second deformable portion is deformeda second deformed portion is created and extends into a seconddepression area that is disposed on an inner portion of the housing ofthe downhole tool, the second deformed portion on the second sleevecreated from forcing a second fluid blocking member past the lipdisposed in the second sleeve.
 17. The tool of claim 1 wherein thedeformable portion is a lip disposed in the first sleeve and once thedeformable portion is deformed a deformed portion is created and extendsinto a depression area that is disposed on an inner portion of a housingor bottom sub of the downhole tool, the deformed portion created fromforcing a fluid blocking member past the lip disposed in the firstsleeve.
 18. A method, the method comprising: positioning a downhole toolin a wellbore, the downhole tool comprising: a flapper valve assemblyfor controlling the backflow of fluid into a tubing string; a firstsleeve slidably disposable within at least a portion of the flappervalve assembly and the downhole tool, the first sleeve slidable from afirst position to a second position; a second sleeve slidably disposablewithin at least a portion of the flapper assembly and the downhole tool,the second sleeve disposed uphole of the first sleeve in the downholetool, the second sleeve slidable from a first position to a secondposition; and a deformable portion incorporated into the first sleevethat is yieldably deformed to maintain the first sleeve in substantiallythe second position; and shifting the first sleeve in the downhole toolto interact with the flapper valve assembly.
 19. The method of claim 18wherein the flapper valve assembly comprises a flapper seat and aflapper that can close against the flapper seat and prevent fluid frompassing in the uphole direction through the downhole tool.
 20. Themethod of claim 19 further comprising the step of shifting the secondsleeve in the downhole tool to interact with the flapper valve assembly.21. The method of claim 20 wherein the flapper is in a closed positionwhen the first sleeve is in its second position and the second sleeve isin its first position.
 22. The method of claim 21 wherein the flapper isin a closed position before the second sleeve is shifted and the flapperis in an open position after the second sleeve is shifted.
 23. Themethod of claim 18 wherein the downhole tool further comprises a seconddeformable portion that is deformed to maintain the second sleeve in thesecond position.
 24. The tool of claim 23 wherein the second deformableportion is a lip disposed in the second sleeve and once the seconddeformable portion is deformed a second deformed portion is created andextends into a second depression area that is disposed on an innerportion of the housing of the downhole tool, the second deformed portionon the second sleeve created from forcing a second fluid blocking memberpast the lip disposed in the second sleeve.
 25. The method of claim 18wherein the deformable portion is a lip disposed in the first sleeve andonce the deformable portion is deformed a deformed portion is createdand extends into a depression area that is disposed on an inner portionof a housing or bottom sub of the downhole tool, the deformed portioncreated from forcing a fluid blocking member past the lip disposed inthe first sleeve.